Production Lines Rail Forging LineChallenge of rail forging Forging of train rail ends is vital for...
Transcript of Production Lines Rail Forging LineChallenge of rail forging Forging of train rail ends is vital for...
State of the Art• Highcapacity:4-8rails/hour
• Save75%ofmanpower
• Save65%onmilling
• Savemorethan50%energy
• Savepostheattreatment
• Hardnessofrailheadsameorbetterthantheinputrail
• Machiningonlyonrailheadandunderfoot
• ReducedHazardZone(HAZ)
• Decarburizationreducedtoaminimum
Production Lines
Rail Forging LineForging to Net Shape
FORGING PRESS5,000tonshydraulicpresswithforgingdies
HEATINGSystemforautomaticheatingofrails
RAIL MANIPULATORSFourcomputer-controlledmanipulatorslift,turnandmoverailsthroughtheentireprocess
RTS PANELOperatorPanelforRailTransferSystem
LUBRICATION
INPUT SECTIONHoldsuptofiverails,readyforpick-up
OUTPUT SECTIONFinishedrails,readyforpick-upandstoring
ADVANCED DIES AND PRESSHighlyspecializedforgingequipment
MANIPULATOR FOR RAIL HANDLING5-axismanipulatorwithservo
Version 1.0 · February 2013
Hydraulico as
Raadhusgade 87 DK-8300 Odder Denmark
Tel.: +45 8780 2000 Fax: +45 8780 0304
Watchvideodocumentationandfindmoreinformationatwww.hydraulico.com
A Complete Solution: Rail ForgingThesystemincludesa5,000tonpresswithspeciallydevelopeddies,heatingandanadvancedcomputer-controlledRailTransferSystem–thiscanboostproductivitysignificantly!
Challenge of rail forging
Forgingoftrainrailendsisvitalforensuringadurable,smoothandsafeshiftingofrailsinrailwaycrossings.However,forging–i.e.formingofpre-heatedobjects–posesseveralchallengestobothpressanddietechnologies.
Forseveralyears,Hydraulicohasbeenworkingintenselyonrefiningthetechnologiesinvolvedintransitionforgingsfromassymetricthickwebrailstothesymmetricrailsection.
Controlling the final shape of forged railsThedesignofthediesisanimportantparametertoperfectthefinalshapeoftheforgedrail.
Hydraulicobenefitsfromadvancedsimulationthathasbeenspeciallydevelopedtodefinethediedesignforoptimumshapeandminimizecostfromdiewear.
Computer simulationsDetailedanalysisofforgingprocesssimulationshasproducedmanyimportantdataforthedesignofforgingdies.
Fast production cycles
TheRailForgingSystemhasfourmanipulatorsthatoperateinperfectcoordination,andthesystemcompletes5-8railsperhour.Eachrailisonlyheatedonce,savingconsiderableamountsoftimeandenergyinthecompleteprocess.
Allforgingoperationsareconductedwithin90seconds,eliminatingtheneedforanextraheating.
Built-in flexibility
Processsurveillanceandcontrolisobtainedviacustomizedcomputersoftware.EveryfunctionaldetailintheRailForgingSystemisprogrammable,andmaybechangedinordertoadapttodifferenttasks,oralternativeproductions.
Other benefits
• Fullyintegratedhandlingofrail,railheating,dieheating,lubrication,forgingandflashremoval
• Thesystemcanhandleraillengthsfrom3metersupto24metersormore
• Documentedprocessparameters:Temperature,pressforce,andcycletime
• Quickdiechange
• Programswithallparametersarestoredforre-use
Reference
HydraulicohasmanufacturedRailForgingSystemstomanufacturersinChina,India,EUandCIS.
Hydraulico presses and production lines are at work around the globe. You will find local representatives in more than 16 major countries worldwide.